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Flywheel Magneto Installation; Stator Removal - Kawasaki KX250F Service Manual

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Flywheel Magneto
Screw the flywheel puller [A] into the flywheel.
Remove the flywheel from the crankshaft by turning in the
puller center bolt and tapping the head of the bolt lightly
with a hammer, while holding the puller body steady.
There is a woodruff key in the crankshaft tapered portion.
Special Tool - Flywheel Puller: 57001–1565
Never strike the grab bar or the flywheel itself.
Strike the bar can bond it. If the flywheel is strike,
the magnets may lose their magnetism.

Flywheel Magneto Installation

Using a high flash-point solvent, clean off any oil or dirt
that may be on the crankshaft taper [A] or in the hole [B]
in the flywheel. Dry them with a clean cloth.
Fit the woodruff key [C] securely in the slot in the crank-
Confirm the flywheel fit or not to the crankshaft before
tightening it with specified torque.
Install the flywheel and tighten it with 45 N·m (4.5 kgf·m,
33 ft·lb) of torque.
Remove the flywheel nut.
Check the tightening torque with flywheel puller.
If the flywheel is not pulled out with 20 N·m (2 kgf·m, 15
ft·lb) of drawing torque, it is installed correctly.
If the flywheel is pulled out with under 20 N·m (2 kgf·m,
15 ft·lb) of drawing torque, clean off any oil dirt or flaw of
the crankshaft and flywheel tapered portion, and dry them
with a clean cloth. Then, confirm that it is not pulled out
with above torque.
Holding the flywheel steady, with the flywheel holder, and
tighten the flywheel nut.
Special Tool - Flywheel Holder : 57001–1567
Torque - Flywheel Nut : 49 N·m (5.0 kgf·m, 36 ft·lb)
Install the magneto cover (see Magneto Cover Installa-

Stator Removal

Magneto Cover (see Magneto Cover Removal)
Stator Bolts [A]
Crankshaft Sensor Bolts [B]
Wiring Holder [C]
Wiring Grommet [D]
Remove the stator [E] and crankshaft sensor [F] as a set.


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   Also See for Kawasaki KX250F

This manual is also suitable for:

Kx250f 2004

Comments to this Manuals

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  • Paul Aug 31, 2015 08:09:
    Does the manual say when to rebuild their 4 stroke bikes
  • Paul Aug 31, 2015 08:24:
    Does the manual say when to rebuild the 250 four stroke bikes